The effect of Mn content on a novel Al-Mg-Si-Sc-Zr alloy produced by laser powder bed fusion: The microstructure and mechanical behavior

Scandium is very expensive and limits the application potential of Sc containing alloys. A novel high-strength Al-Mg-Mn-Sc-Zr alloy was designed for reducing Sc. Multiple strengthening mechanisms were utilized for designing this alloy, especially for the solid solution strengthening which benefits from ultrahigh cooling. With the addition of Mn and Si, the strength of our alloy reaches comparable level of similar alloys while the Sc content is 40-60 % less than them. The effect of Mn addition on microstructure and mechanical properties were carefully studied. Near full-dense samples with relative density >99.88 % were obtained with the help of overlapping prediction model. The continuous Mg2Si network was observed with Si introduction and broken up with increasing Mn content. According to the tensile experiment results and corresponding calculations, it was considered that the thermal stability and the effect of precipitate strengthening was slightly deteriorated. However, obvious improvement of the tensile strength was observed with increasing Mn addition, and the ductility maintains in a certain range. After aging at 280 degrees C for 4 h, the sample of 1.4 wt% Mn exhibits the highest ultimate strength of 497.08 +/- 7.22 MPa, and possesses a considerable ductility of 8.01 +/- 0.34 %. The Portevin-Le Chatelier (PLC) effect was observed in stress-strain curves, which reflects a dynamic strain aging of mobile dislocations and solute atoms. After aging, the stress amplitude and waiting time of serration flow decrease obviously, because of the introduction of bypassing precipitates and reduction of diffusion time. Compared with other similar alloys, our alloy exhibited comparable yield strength and elongation, but considerable advantages in material costs resulting from lower Sc content. It will offer not only an idea for alloy design utilizing the ultra-high solid solubility of elements, but also a feasible way to further expand application field of high-strength Al-based alloys through reducing the material costs.